Composite component integration panel for a motor vehicle

ABSTRACT

A panel assembly is securable to a front end of a motor vehicle for positioning and securing a plurality of elements thereto. The panel assembly has a core connectable to the front end of a motor vehicle. A skin covers the core. A component mounting structure is molded to the skin. The component mounting structure is adapted to have the plurality of elements attached thereto in spaced relation. The panel assembly may be assembled to the motor vehicle with the plurality of elements secured thereto.

FIELD OF THE INVENTION

[0001] The invention relates to a composite component integration panelfor an automotive vehicle. More particularly, the invention relates to afront end assembly of a motor vehicle that integrates automotivecomponents typically found in a forward section of a motor vehicle.

DESCRIPTION OF THE RELATED ART

[0002] A grille opening reinforcement (GOR) is one of the most importantcomponents of the front end of an automobile. A GOR is a molded piecehaving a Class “B” surface, i.e., a surface that is not visible when themotor vehicle is fully assembled. Components such as fenders, bumpercovers, grilles, headlamps and the like are assembled to the GOR. TheGOR provides attachments, locators and structural support to thecomponents that are secured thereto. It also provides access for lampbulb replacement, secondary hood latch release levers, and othermaintenance and repair requirements.

[0003] The primary function of a GOR is to provide the assembly plants acontrolled and predictable front-end composite structure for theirvehicles. An original equipment manufacturer (OEM) typicallyincorporates the GOR into all of its designs because the fit and finishof all front-end exterior components are maintained at a high level withgreat precision. However, a disadvantage of GOR designs is that much ofthe structure of the GOR is duplicated by a similar structure, namely,the radiator support.

SUMMARY OF THE INVENTION

[0004] Accordingly, a panel is provided for front-end structure, crashmanagement, and attaching components to a front end of a vehicle body.The panel eliminates duplication of structure between a conventionalradiator structure and the GOR. The panel could be installed in either abody shop or trim line application. The trim line application wouldallow for additional component integration: For example, parts such asheadlamps, park turn lamps, grille, radiator, fascia, fluid reservoirs,and air dams could first be assembled to the panel, thus forming afront-end module, which would then be attached to the body structure.Therefore, the panel would not have an impact on a traditional body shopbuild but more importantly would have the flexibility of added partconsolidation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Advantages of the invention will be readily appreciated as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

[0006]FIG. 1 is a perspective view of a first embodiment of theinvention;

[0007]FIG. 2 is a perspective view of the first embodiment of theinvention in complete form;

[0008]FIG. 3 is a partially cut-away perspective view of the firstembodiment of the invention;

[0009]FIG. 4 is a partially cut-away perspective view of a secondembodiment of the invention;

[0010]FIG. 5 is a partially cut-away perspective view of a thirdembodiment of the invention;

[0011]FIG. 6 is a partially cut-away perspective view of a fourthembodiment of the invention;

[0012]FIG. 7 is a perspective view of a fifth embodiment of theinvention; and

[0013]FIG. 8 is a perspective view of the fifth embodiment of theinvention in complete form.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] As shown in the Figures, wherein like primed numerals representsimilar elements in different embodiments, a panel assembly of thepresent invention is generally indicated at 10. The panel assembly 10 isan open structural frame having an upper section 12 and a lower section14. The lower section 14 includes a cross member 16 and two side members18, 20 creating a U-shape. Each of the upper 12 and lower 14 sectionshas a core 22 and a skin 24. In the preferred embodiment, the core 22 isfabricated from balsa wood and the skin 24 is fabricated from a fiberresin matrix, such as a carbon fiber. The balsa wood core 22 is insertedinto a mold, which is subsequently shot with the carbon fiber. Thecarbon fiber skin 24 is applied to the balsa core 22 and serves as atensile member in impact situations.

[0015] The upper section 12 defines a length 26 that extends between adriver end 28 and a passenger end 30. The length 26 extends through anon-linear path in the preferred embodiment. Each of the driver 28 andpassenger 30 ends include joint connections 32, 34, best seen in FIG. 7.The joint connections 32, 34 will be discussed in greater detailsubsequently.

[0016] The lower section 14 extends between an upper driver end 36 andan upper passenger end 38. More specifically, one 20 of the side members18, 20 ends at the upper driver end 36 and the other 18 of the sidemembers 18, 20 ends at the upper passenger end 38. The upper driver 36and passenger 38 ends are fixedly secured to the length 26 of the uppersection 12 between the driver 28 and passenger 30 ends thereof.

[0017] As detailed in FIG. 3, the carbon fiber skin 24 is shaped in apartial C-section. The C-section allows for increased structuralintegrity and facilitates wet out in the molding process. The carbonfiber skin 24 includes a first skin portion 40 and a second skin portion42 that together envelop the core 22. This process of manufacture is viamolding, as alluded to above.

[0018] The panel assembly 10 is inserted into a compression mold, thusallowing for intricate shapes and attachment features to be molded in acomponent mounting structure 44, shown in FIG. 2. After the panelassembly 10 is inserted in the tool, a thermoplastic/glass reinforcedmaterial fills the mold via a compression or injection molding process.During the molding process, the thermoplastic/glass reinforced materialis essentially in a liquid state, which allows for complete materialdistribution and wet out to the panel assembly 10. These aforementionedprocesses serve two main functions. First, the carbon fiber skin 24 andbalsa wood core 22 are completely encapsulated (box section) with astructural skin 46. Second, module formation of the head lamp, fascia,grille, radiator, and body structure attachments can be performed awayfrom assembly of a motor vehicle.

[0019] Calculations can demonstrate the composite panel's attributes asthey relate to vehicle stiffiess and crash worthiness are far superiorto steel structural counterparts. The mass moment of inertia propertiesfor the panel assembly 10 in the Z-direction, e.g., the direction of animpact, reap significant magnitudes of improvement in comparison to theimpact directional mass moment of inertia properties of the steelstructure.

[0020] A test was performed with the loading criteria input based on a4500 pound vehicle subject to 40% offset/40 mile per hour deformablebarrier impact. This test yielded a resultant point load (offset fromvehicle centerline) of 50,000 pounds. Due to the ultimate tensilestrength of steel being exceeded by the stress of the loading condition,the results yielded a catastrophic failure in the steel radiatorstructure. The comparison of deflection and stresses between the panelassembly 10 and the steel radiator structure demonstrates that the panelassembly 10 would significantly improve vehicle stiffness and crashworthiness.

[0021] An additional crash energy attribute of the panel assembly 10 isin the design of the joint connections 32, 34 to the shotgun rails (notshown). The joint connections 32, 34, as shown in FIG. 7, would hold theshotgun rails of the motor vehicle and be attached with a through bolt,thus coupling the two upper shotgun rails. Under an offset/high speedcrash similar to that discussed above, the coupling of the uppershotguns enables the energy due to impact will be dissipated througheach side of the motor vehicle.

[0022] Lastly, relative to energy management, the panel assembly 10 isadvantageous in terms of pedestrian protection (upper leg/lower torso togrille/hood impact). These advantages may be attributed to the sandwichconstruction of the panel assembly 10, as it has the ability todistribute local loads and stresses over a large area. This equates to alower HIC (head impact criteria) value upon pedestrian impact.

[0023] A mass comparison of the panel assembly 10 and the steel radiatorstructure for a typical passenger vehicle such as a midsize motorvehicle (a family sedan) yielded the following results: the steelradiator structure (upper rail portion only) weighed 6.6 pounds incomparison to 5.33 pounds for the panel assembly 10. The overallapproximate weight of the steel radiator structure and panel assembly10, without lamp canisters or integrated air deflectors, are 15.5 and8.14 pounds, respectively. Therefore, improvements of energy dissipationare matched by the reduction in weight to the motor vehicle.

[0024] The invention has been described in an illustrative manner. It isto be understood that the terminology, which has been used, is intendedto be in the nature of words of description rather than of limitation.Many modifications and variations of the invention are possible in lightof the above teachings. Therefore, within the scope of the appendedclaims, the invention may be practiced other than as specificallydescribed.

What is claimed is:
 1. A panel assembly securable to a front end of a motor vehicle for positioning and securing a plurality of elements thereto, said panel assembly comprising: an upper section defining a length extending between a driver end and a passenger end; a lower section extending between an upper driver end and an upper passenger end, said upper driver and passenger ends fixedly secured to said length of said upper section; and a component mounting structure molded to said skin of said upper and lower sections, said component mounting structure adapted to have the plurality of elements secured thereto in spaced relation such that said panel assembly may be assembled to the motor vehicle with the plurality of elements secured to said panel assembly, characterized by said upper and lower sections each comprising a molded skin encapsulating a core and said component mounting structure comprising a flange extending away from said core.
 2. A panel assembly as set forth in claim 1 wherein said skin includes a first skin portion and a second skin portion, said first skin portion covers a portion of said core and said second skin portion cooperates with said first skin portion, encapsulating said core.
 3. A panel assembly as set forth in claim 2 wherein said core is fabricated of balsa wood.
 4. A panel assembly as set forth in claim 3 wherein said skin includes carbon fiber.
 5. A panel assembly as set forth in claims 1 to 4 wherein said first skin portion includes said flange.
 6. A panel assembly as set forth in claim 5 wherein said second skin portion includes said flange.
 7. A panel assembly as set forth in claim 6 wherein said upper section includes joint connections disposed at said driver end and said passenger end. 